Lightweight Composite Floor Panel Assembly With Fire-Retardant Sheathing
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Solution Overview
Problem
Existing prefabricated floor structures lack fire retardancy, are heavy, and are not compatible with sustainable materials, making them unsuitable for refurbishment and installation in existing structures.
Innovation Solution
A lightweight composite panel assembly comprising parallel end joists, web plates forming channels, and a structural sheathing layer with a fibre mesh impregnated resin system, which is fire retardant and easy to install, using wood composite materials and a bio-resin binder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional prefabricated floor structures (steel-cement-composite) are used, then structural strength and load-bearing capacity are improved, but weight increases significantly requiring strong foundation walls
Solution Approach 1:
The patent employs a composite construction combining wood-based panels (OSB or plywood) with steel reinforcement elements and concrete infill. This composite approach achieves the required structural strength and fire retardancy while maintaining lower weight compared to traditional solid concrete or steel-cement-composite floors. The wood provides dimensional stability and fire resistance, steel adds tensile strength, and concrete provides compressive strength, creating an optimized weight-to-strength ratio.
2Stability of the object's composition
If cement-based prefabricated floors are used, then structural integrity is improved, but compatibility with floor coverings and workability deteriorate
Solution Approach 1:
The floor structure is segmented into distinct functional layers: wood-based panels for dimensional stability and fire resistance, steel reinforcement for tensile strength, concrete infill for compressive strength, and a separate topping layer for floor covering compatibility. This segmentation allows each layer to be optimized for its specific function while maintaining overall structural integrity, and the modular design improves ease of manufacture and assembly.
3Weight of stationary object
If wood-concrete construction members are used, then weight is reduced compared to reinforced concrete, but fire retardancy is insufficient without extensive treatment
Solution Approach 1:
The patent creates a fire-resistant composite system where wood-based panels are combined with non-combustible steel reinforcement and concrete infill. The steel and concrete components provide inherent fire retardancy, protecting the wood elements during fire exposure. This composite approach achieves fire safety requirements without requiring extensive chemical fire-retardant treatments of the wood, maintaining the weight advantages of wood-concrete construction while ensuring fire protection.
4Ease of operation
If integrated single-piece floor units are manufactured, then installation time and on-site assembly complexity are reduced, but manufacturing complexity and quality control requirements increase
Solution Approach 1:
The floor structure is designed as a segmented composite unit with distinct layers (wood panels, steel reinforcement, concrete infill, topping) that can be manufactured separately and then assembled into an integrated single-piece unit. This segmentation allows each component to be manufactured using optimized processes with rigorous quality control, then assembled through standardized connection details, reducing overall manufacturing complexity while achieving the benefits of integrated installation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The assembly provides enhanced fire retardancy, reduced weight, and compatibility with building services, allowing easy installation and refurbishment of existing structures while maintaining structural integrity.
Implementation Method 1
a fibre mesh impregnated with a resin and curing agent... joining the joins and web plate to the upper and lower surface by providing strips of the fibre mesh impregnated with a resin and curing agent as adhesive joints upon curing
Implementation Method 2
subjecting the precured assembly to a curing process under conditions that are suitable for crosslinking the resin, wherein curing temperature, curing speed, viscosity, water content, and curing pressure such to compress the impregnated fibre mesh and allow for ingression of at least part of the resin into the assembly prior to curing
Data Source
AI summary
The present invention relates to a lightweight composite architectural panel assembly, comprising: a) at least a first and a second end joist spaced parallelly along a perimeter of the assembly, each having a length; b) at least one web plate spaced parallelly between the end joists; an upper surface arranged in parallel to a lower surface; and attached to the at least first and a second end joist and the web plate, forming one or more channels disposed vertically between the upper and lower surfaces and longitudinally extending along the upper and lower surfaces, thereby forming an open-ended boxlike body; and c) a structural vertically load-bearing sheathing layer enveloping and adherent to the outer surface of the open-ended boxlike body, wherein the sheathing layer comprises a composite skin comprising a fibre mesh and a crosslinked polymeric resin system.